CN110792490B

CN110792490B - Inner box flow deflector for a vehicle exhaust system mixer assembly

Info

Publication number: CN110792490B
Application number: CN201910711626.6A
Authority: CN
Inventors: L·波因索; L·库尼
Original assignee: Faurecia Exhaust Systems
Current assignee: Faurecia Exhaust Systems
Priority date: 2018-08-03
Filing date: 2019-08-02
Publication date: 2022-09-13
Anticipated expiration: 2039-08-02
Also published as: US20200040793A1; US10907522B2; CN110792490A; DE102019120994A1

Abstract

A mixer includes a baffle having a baffle inlet that receives exhaust from an upstream exhaust component and a baffle outlet that directs the exhaust to a downstream exhaust component. The cover is provided with a chamber between the inner surface of the cover and the baffle. The inner box is positioned within the chamber to cover the baffle outlet and includes a bottom wall having a peripheral wall extending around at least a portion of a periphery of the bottom wall. At least one deflector wall is located within the inner box to provide a wall surface spaced from the peripheral wall to define an internal flow path that diverts the exhaust gas at least partially around the baffle outlet before the exhaust gas exits the baffle outlet. An opening is in the peripheral wall to receive exhaust gas exiting the inlet and direct the exhaust gas into the internal flow path.

Description

Inner box flow deflector for a vehicle exhaust system mixer assembly

Background

The exhaust system directs hot exhaust gases produced by the engine through various exhaust components to reduce emissions and control noise. The exhaust system includes an injection system having a doser that injects a solution of a reductant, such as urea and water, upstream of a Selective Catalytic Reduction (SCR) catalyst. The mixer is located upstream of the SCR catalyst and mixes the engine exhaust and the products of the urea conversion.

The dosers typically inject a reductant into the exhaust stream. When the spray contacts the inner surface of the mixer, urea deposits may form that can impede the flow of exhaust gas and reduce SCR catalyst performance over time. It is important to configure the mixer assembly with mixing elements so that the spray and the exhaust gas are completely mixed together before entering the SCR catalyst.

Disclosure of Invention

In one exemplary embodiment, the mixer assembly includes at least one baffle having a baffle inlet that receives exhaust gas from an upstream exhaust component and a baffle outlet that directs the exhaust gas to a downstream exhaust component. The cover provides a chamber between an inner surface of the cover and the baffle. The inner box is located within the chamber to cover the baffle outlet and includes a bottom wall having a peripheral wall extending around at least a portion of a periphery of the bottom wall. At least one deflector wall is located within the inner box to provide a wall surface spaced from the peripheral wall to define an internal flow path that diverts the exhaust gas at least partially around the baffle outlet before the exhaust gas exits the baffle outlet. Openings are located in (on) the peripheral wall to receive exhaust gas exiting the baffle inlet and direct the exhaust gas into the internal flow path.

In another exemplary embodiment, a vehicle exhaust system includes at least one of an upstream catalyst and/or filter, at least one downstream catalyst, and a mixer assembly connecting an outlet from the at least one of the upstream catalyst and/or filter to an inlet to the at least one downstream catalyst. The mixer assembly includes at least one baffle having a baffle inlet that receives exhaust gas from at least one of the upstream catalyst and/or the filter and a baffle outlet that directs the exhaust gas to at least one downstream catalyst, a cover having a base wall including an outer wall extending around a periphery of the base wall to define a chamber between an inner surface of the cover and the at least one baffle, and an inner box located within the chamber. The inner box includes a bottom wall having a peripheral wall extending around at least a portion of the periphery of the bottom wall, and the box is located between the base wall of the cover and the baffle outlet to leave an open volume between the base surface and the baffle inlet. At least one deflector wall is located within the inner box to provide a wall surface spaced from the peripheral wall to define an internal flow path that diverts the exhaust gas at least partially around the baffle outlet before the exhaust gas exits the baffle outlet. Openings are located in (on) the peripheral wall to receive exhaust gas exiting the baffle inlet and direct the exhaust gas into the internal flow path.

In another embodiment of any of the above, an injector is mounted on the cover to inject the reducing agent to mix with the exhaust gas, and wherein the injector is positioned to inject the reducing agent in a direction toward the opening in the outer peripheral wall.

In another embodiment of any of the above, the at least one baffle comprises a first baffle and the chamber comprises a first chamber, further comprising a second baffle located on an opposite side of the first baffle from the cover to define a second chamber, and wherein the outlet of the first baffle directs the mixture of the exhaust gas and the reductant into the second chamber.

In another embodiment of any of the above, the wall surface of the deflector wall has a first portion having a first side facing the first wall and a second side facing the second wall, and wherein the wall surface includes a second portion curved from one end of the first portion to face the opening.

In another embodiment of any of the above, the wall surface includes a third portion that curves from an opposite end of the first portion to direct the mixture of reductant and exhaust gas around the outlet.

Drawings

These and other features of the present application will be best understood from the following specification and drawings, the following of which is a brief description.

FIG. 1 schematically illustrates one example of an exhaust system component having a mixer assembly according to the present disclosure.

Fig. 2 is a side view of the system shown in fig. 1.

Fig. 3 is a perspective view of a mixer assembly having a cover, baffles, an inner box, and deflector walls.

Fig. 4 is a view similar to fig. 3 but with a portion of the cover removed.

Fig. 5 is a top view of the baffle.

Fig. 6 is a view similar to fig. 3 but with the cover removed.

Fig. 7 is a view similar to fig. 6 but showing the deflector wall located within the inner box.

Fig. 8 is a cross-sectional view of the mixer assembly.

FIG. 9 is a top view of one embodiment of an internal flow path within the inner box.

Fig. 10 is another embodiment of an internal flow path.

FIG. 11 is another embodiment of an internal flow path.

Detailed Description

FIG. 1 shows a schematic diagram of a vehicle exhaust system 10 that directs hot exhaust gases produced by an engine 12 through various upstream exhaust components 14 to reduce emissions and control noise, as is known. In one example configuration, the upstream exhaust component 14 directs exhaust gas into a Diesel Oxidation Catalyst (DOC)16 and then into a Diesel Particulate Filter (DPF)18, as is known for removing pollutants from exhaust gas. Downstream of DOC 16 and DPF 18 are one or more Selective Catalytic Reduction (SCR) catalysts 20. A solution of a reducing agent, such as urea and water, is mixed with the exhaust gas for selective catalytic reduction of NOx, thereby reducing the emission of NOx in the exhaust system in a known manner.

As shown in FIG. 2, in one example, the DOC 16, DPF 18, and SCR catalyst(s) 20 are enclosed within a common housing 22. The housing 22 has an inlet 24 that receives exhaust gas from the engine 12 and any upstream exhaust component 14, and has an outlet 26 that directs the exhaust gas to a downstream exhaust component 28. The various downstream exhaust components 28 may include one or more of the following: pipes, filters, valves, additional catalysts, mufflers, etc. These upstream and

downstream components

14, 28 may be installed in a variety of different configurations and combinations depending on the vehicle application and available packaging space.

The mixer assembly 30 is located downstream of the DOC 16 and DPF 18 and upstream of the SCR catalyst 20. The mixer assembly 30 is used to generate a swirling or rotational motion or helical flow of the exhaust gas. The construction of the mixer assembly 30 will be discussed in more detail below.

An injection system 32 (fig. 2) is used to inject a solution of a reductant, such as urea and water, into the exhaust flow upstream of SCR catalyst 20 so that mixer assembly 30 may completely mix the urea and exhaust gases together. The injection system 32 includes a fluid supply 34, an injector or doser 36, and a controller 38 that controls injection of the reductant as is known. Any type of known supply 34 and known injector/doser 36 may be used with the mixer assembly 30. The construction and operation of the supply 34 and the injector/doser 36 are well known and will therefore not be discussed in detail.

One example of the mixer assembly 30 is shown in more detail in fig. 3-8. In this example, the mixer assembly 30 includes a cover 40, a first baffle 42, and an inner box 44. The cover 40 has a connection interface configured for attachment to the baffle 42 and/or the housing 22. The cover 40 may be connected to the baffle 42 and/or the housing 22 at the connection interface in a welded, brazed, fastened, etc. manner. As shown in fig. 5, the baffle 42 has a baffle inlet 46 that receives exhaust gas exiting the DPF 18 and a baffle outlet 48 that directs a mixture of reductant and exhaust gas to the SCR catalyst(s) 20.

The cover 40 includes a base wall 50 with an outer wall 52 extending outwardly from the base wall 50 around the periphery of the base wall 50. The base wall also includes a solid plate-like structure that encloses the baffle 42 between the cover 40 and the housing 22. The cover 40 provides a chamber 54 (fig. 4) between the first baffle 42 and the inner surface of the cover 40. The inner box 44 is located within the chamber 54 and includes a bottom surface 56, the bottom surface 56 having a peripheral wall 58 extending around at least a portion of the periphery of the bottom surface 56. The bottom surface 56 is provided by a solid base wall 56a forming the plate-like bottom of the cassette structure. The peripheral wall 58 forms each solid side wall of the box structure to prevent exhaust gas from flowing directly from the baffle inlet 46 to the baffle outlet 48. In one example, the peripheral wall 58 of the inner box 44 has four sidewalls to define a square or rectangular shape; however, it should be understood that the cassette 44 may have fewer or additional (additional) discrete (discontinuous) side walls. Alternatively, the peripheral wall 58 may be curved to provide an oval or circular shaped box.

In one example, the inner box 44 is positioned to cover only the baffle outlet 48, leaving the baffle inlet 46 uncovered, as shown in fig. 6. At least one deflector wall 60 is located within the inner box 44 to provide a wall surface 62 spaced from the outer peripheral wall 58 to define an internal flow path 64, the internal flow path 64 diverting the mixture of reductant and exhaust gas at least partially around the baffle outlet 48 before exiting the baffle outlet 48. An opening 66 is provided in the peripheral wall 58 to receive exhaust gas exiting the baffle inlet 46 and direct the exhaust gas into the internal flow path 64. The opening 66 is preferably located at a position that is not in the portion of the peripheral wall 58 facing the baffle inlet 46.

In one example, the doser 36 is mounted to the cover 40 to inject the reducing agent in a direction toward the opening 66 in the outer peripheral wall 58. The cover 40 includes an opening 68 (fig. 3) in the peripheral wall 52, the opening 68 being located at a position facing the opening 66. The injection axis I (fig. 5) extends in a direction directly into the internal flow path 64 of the inner box 44 and does not directly face the baffle inlet 46 or outlet 48. This provides more uniform mixing of the reductant R and exhaust E and reduces deposits forming within the mixer assembly 30.

As described above, the cover 40 is provided with the cavity 54 between the first baffle 42 and the inner surface of the cover 40. The inner box 44 is located between the base wall 50 of the cover and the baffle outlet 48, which leaves an open volume between the base wall 50 and the baffle inlet 46 as shown in fig. 3.

In one example, the mixer assembly 30 includes a second baffle 70 located on a side of the first baffle 42 opposite the cover 40. The second baffle defines a second chamber 72 (fig. 4) on a side of the first baffle 42 opposite the first chamber 54. The baffle outlet 48 of the first baffle plate 42 directs the mixture of exhaust gas and reductant into the second chamber 72. In one example, the second baffle 70 includes a second baffle inlet 74 facing the baffle inlet 46 of the first baffle 42 and one or more second (secondary) baffle outlets 76 facing the SCR catalyst 20. The number of secondary baffle outlets 76 may vary from a single outlet up to five or more outlets.

In one example, DOC 16, DPF 18, and SCR 20 exhaust components are enclosed within a common housing 22 connected to a second baffle 70. In another example, a downstream exhaust component, such as the SCR catalyst(s) 20, is located within the second chamber 72 such that the second baffle 70 forms a portion of the common housing 22.

As shown in the example of fig. 6, the outer peripheral wall 58 of the inner box 44 includes at least a first wall 58a extending between the baffle inlet 46 and the baffle outlet 48, a second wall 58b opposite the first wall 58a, a third wall 58c connecting the first wall 58a to the second wall 58b, and a fourth wall 58d opposite the third wall 58c and having an opening 66. In one example, the deflector wall 60 has a first wall portion 60a and a second wall portion 60b, the first wall portion 60a having a first side facing the first wall 58a and a second side facing the second wall 58b, the second wall portion 60b being bent from one end of the first wall portion 60a to face the opening 66. The deflector wall 60 may also include a third wall portion 60c that curves from the opposite end of the first wall portion 60a to direct the mixture of reductant and exhaust gas around the baffle outlet 48.

As shown in fig. 8, in one example, a gap 80 is formed between the bottom wall 56a of the inner box 44 and the base wall 50 of the cover 40. The gap 80 may be an open gap that receives exhaust gases, or the gap may be at least partially filled with an insulating material 82. There may also be a gap 80 between the second wall 58b and/or the third wall 58c of the inner box 44 and the peripheral wall 52 of the cover 40. The gap 80 may be an air gap or filled with an insulating material 82. The gap(s) 80 may be used to control the inner wall temperature, e.g., the temperature inside the inner box 44, to reduce the likelihood of deposit formation.

There is also a gap 84 between the fourth wall 58d and the peripheral wall 52 of the cover 40. The gap 84 is an open gap that forms part of the flow path from the baffle inlet 46 to the opening 66 in the inner box 44.

In one example, the inner box 44 and/or the at least one baffle 42 may include at least one perforated region 90 to provide a bypass. The perforated area 90 can be used to reduce back pressure in the mixer assembly 30 as desired. Examples of locations where the perforated region 90 may be located include: in wall 58a and/or wall 58b and/or wall 58c and/or wall 58d and/or wall 56a and/or wall 60b and/or wall 60 c. Fig. 6 shows an example where the perforated area 90 is located in the base wall 56 a. The perforated region 90 may be located in only one location or in multiple locations.

The inner box 44 defines an interior volume between the first baffle 42 and the inner surface of the box 44 that communicates with the baffle outlet 48. The inner box 44 covers only the baffle outlet 48 and includes an opening 66 to allow the mixture of reductant and exhaust gas to pass from the first chamber 54 into the interior volume. The deflector wall 60 is located within the inner box 44 such that a conduit/pipe is formed extending from the opening 66 to the baffle outlet 48. The length of the conduit and the location and orientation of the deflector wall 60 in the inner box 44 improves the overall mixing of the reductant and exhaust gases. Additional deflector walls or other mixing elements 92 may also be included within the cartridge 44 to further improve mixing, as schematically shown at 92 in fig. 9. Additional mixing elements may also be associated with the cover 40 and/or the first baffle 42, as schematically shown at 94.

FIG. 9 illustrates an example of a first flow configuration in which exhaust gas enters the gap 84 to mix with the injected reductant, and the mixture is directed through the opening 66 of the cartridge 44 and into the internal flow path 64. The deflector wall 60 prevents the mixture from exiting directly from the outlet 48 and redirects the mixed flow at least once before exiting the cartridge 44. Fig. 11 is similar to fig. 9, but shows the mixture changing direction at least twice within the box 44.

Fig. 10 illustrates an alternative location and/or shape of the baffle outlet 48. In this example, the opening 66 is located in the second wall 58b of the cartridge 44, rather than the fourth wall 58 d. In this example, the exhaust gas flows in a first direction 96 in the gap 84, then changes direction and flows in a second direction 98 in a gap 100 between the cover 40 and the second wall 58 b. The flow enters the opening 66 and the deflector wall 60 prevents the mixture from directly exiting the outlet 48 and redirects the mixed flow at least once before exiting the cartridge 44.

The inner box 44 may be attached to the first baffle 42 by, for example, welding, brazing, or the like. The inner box 44 may be formed of multiple pieces attached to one another or may be formed as a single piece structure. The deflector wall 60 may be integrally formed with the cassette 44 or separately attached.

The present invention provides a mixing duct configuration with a single doser that thoroughly mixes the reducing agent and exhaust gas before they enter the downstream exhaust component. The mixing duct configuration utilizes an inner box in conjunction with an inner deflector wall to define a flow directing channel around the periphery of the mixer outlet. Furthermore, the use of deflector walls within the inner box increases the mixing length to ensure that the reductant is thoroughly mixed with the exhaust gas and evenly distributed over the SCR catalyst or catalysts.

Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.

Claims

1. A mixer assembly for a vehicle exhaust component comprising:

at least one baffle plate having a baffle plate inlet to receive exhaust gas from an upstream exhaust component and a baffle plate outlet to direct exhaust gas to a downstream exhaust component;

a cover configured to provide a cavity between an inner surface of the cover and at least one of the baffles, wherein the cover includes a base wall having an outer wall extending around a periphery of the base wall to define the cavity between the at least one baffle and the inner surface of the cover;

an inner box located within the chamber, the inner box comprising a bottom wall having a peripheral wall extending around at least a portion of a periphery of the bottom wall, and wherein the inner box is positioned to cover the baffle outlet;

at least one deflector wall located within the inner box to provide a wall surface spaced from the peripheral wall to define an internal flow path that diverts the exhaust gas at least partially around the baffle outlet before the exhaust gas exits the baffle outlet;

an opening in the peripheral wall to receive the exhaust gas exiting the baffle inlet and direct the exhaust gas into the internal flow path; and

wherein the bottom wall of the inner box and the base wall of the cover are spaced apart from each other such that the bottom wall and the base wall are separated from each other by an insulating gap.

2. The mixer assembly according to claim 1 comprising an injector mounted to the cover to inject the reductant to mix with the exhaust gas, and wherein the injector is positioned to inject the reductant upstream of the opening in the peripheral wall.

3. The mixer assembly according to claim 2 wherein the inner box is located between the base wall and the baffle outlet, and wherein there is an open area between the base wall and the baffle inlet.

4. The mixer assembly according to claim 3 wherein at least one of the baffles comprises a first baffle and the chamber comprises a first chamber and comprises a second baffle located on an opposite side of the first baffle from the cover to define a second chamber, and wherein the baffle outlet from the first baffle directs a mixture of exhaust gas and reductant into the second chamber.

5. The mixer assembly according to claim 4 wherein the second baffle includes a second inlet facing the baffle inlet of the first baffle and one or more secondary outlets facing the downstream exhaust component.

6. The mixer assembly according to claim 5 wherein the downstream exhaust component includes one or more SCR catalysts.

7. The mixer assembly according to claim 5 wherein the upstream and downstream exhaust components are enclosed within a common housing connected to the second baffle plate.

8. The mixer assembly according to claim 4 wherein the downstream exhaust component is located within the second chamber.

9. The mixer assembly according to claim 3 wherein the outer peripheral wall of the inner box includes at least a first wall extending between the baffle inlet and the baffle outlet, a second wall opposite the first wall, a third wall connecting the first wall to the second wall, and a fourth wall opposite the third wall and including the opening.

10. The mixer assembly according to claim 9 wherein the wall surface of the deflector wall has a first portion having a first side facing the first wall and a second side facing the second wall, and wherein the wall surface includes a second portion curved from one end of the first portion to face the opening.

11. The mixer assembly according to claim 10 wherein the wall surface includes a third portion that curves from an opposite end of the first portion to direct the mixture of reductant and exhaust gas around the baffle outlet.

12. The mixer assembly according to claim 1 wherein the at least one gap comprises an open air gap.

13. The mixer assembly according to claim 1, comprising an insulating material at least partially filling the insulating gap.

14. The mixer assembly according to claim 1 wherein the inner box and/or at least one of the baffles includes at least one perforated area to provide a bypass.

15. The mixer assembly according to claim 1 wherein an inner box is located between the base wall of the cover and the baffle outlet such that a first side of the bottom wall faces the inner surface of the base wall of the cover and a second side of the bottom wall faces the baffle outlet, leaving an open volume between the base wall and the baffle inlet, the open volume being separated from the baffle outlet by the peripheral wall and the bottom wall of the inner box.

16. The mixer assembly according to claim 1 wherein the outer peripheral wall of the inner box has a plurality of side walls to define a square shape or a rectangular shape, and wherein the insulation gap comprises at least a first gap between the bottom wall of the inner box and the base wall of the cover and a second gap between one or more of the plurality of side walls of the inner box and an outer wall of the cover.

17. A vehicle exhaust system comprising:

at least one of an upstream catalyst and/or filter;

at least one downstream catalyst; and

a mixer assembly connecting an outlet of at least one of the upstream catalyst and/or filter to an inlet of at least one of the downstream catalysts, wherein the mixer assembly comprises:

at least one baffle having a baffle inlet to receive exhaust from at least one of the upstream catalyst and/or filter and a baffle outlet to direct exhaust to at least one of the downstream catalysts,

a cover comprising a base wall having an outer wall extending around a periphery of the base wall to define a cavity between at least one of the baffles and an inner surface of the cover;

an inner box located within the chamber, the inner box comprising a bottom wall having a peripheral wall extending around at least a portion of a periphery of the bottom wall, and wherein the inner box is located between the base wall of the cover and the baffle outlet leaving an open volume between the bottom wall and the baffle inlet;

at least one deflector wall located within the inner box to provide a wall surface spaced from the peripheral wall to define an internal flow path that diverts exhaust gas at least partially around the baffle outlet before the exhaust gas exits the baffle outlet;

an opening in the peripheral wall to receive exhaust gas exiting the baffle inlet and direct exhaust gas into the internal flow path, and

18. The vehicle exhaust system according to claim 17 wherein at least one of the upstream catalyst and/or filter and at least one of the downstream catalysts are enclosed within a common housing.

19. The vehicle exhaust system according to claim 17 including an injector mounted to the cover to inject reductant to mix with the exhaust gas, and wherein the injector is positioned to inject reductant upstream of the opening in the peripheral wall.

20. The vehicle exhaust system according to claim 17 wherein at least one of the baffles comprises a first baffle and the chamber comprises a first chamber and comprises a second baffle located on an opposite side of the first baffle from the cover to define a second chamber, and wherein the baffle outlet from the first baffle directs a mixture of exhaust gas and reductant into the second chamber.

21. The vehicle exhaust system according to claim 17 wherein the insulation gap comprises an open air gap or is at least partially filled with an insulating material.

22. The vehicle exhaust system according to claim 17 wherein the outer peripheral wall of the inner box includes at least a first wall extending between the baffle inlet and the baffle outlet, a second wall opposite the first wall, a third wall connecting the first wall to the second wall, and a fourth wall opposite the third wall and including the opening, and wherein a wall surface of the deflector wall has a first portion having a first side facing the first wall and a second side facing the second wall, and wherein the wall surface includes a second portion bent from one end of the first portion to face the opening.

23. The vehicle exhaust system according to claim 17 wherein the inner box is positioned to cover the baffle outlet such that a first side of the bottom wall faces the inner surface of the cover and a second side of the bottom wall faces the baffle outlet, and wherein the open volume between the base wall and the baffle inlet is separated from the baffle outlet by the outer peripheral wall and the bottom wall of the inner box.

24. The vehicle exhaust system according to claim 17 wherein the peripheral wall includes an inner surface facing the at least one deflector wall and an outer surface facing opposite the inner surface, and wherein the insulation gap includes at least a first gap between the bottom wall of the inner box and the base wall of the cover and a second gap between an outer surface of the peripheral wall of the inner box and an outer wall of the cover.